Integrated photovoltaic roofing shingles, methods, systems, and kits thereof

ABSTRACT

Some embodiments of the present disclosure relate to an integrated photovoltaic (PV) roofing shingle comprising a photovoltaic (PV) module and a roofing shingle. In some embodiments, the roofing shingle is bonded to the PV module. In some embodiments, a bond strength between the roofing shingle and the PV module is from 5 N/mm to 60 N/mm tested according to ASTM D1876. In some embodiments, the integrated PV roofing shingle has a mass per unit area of 0.5 lb per square foot to 5 lbs per square foot. Methods, systems, and kits including the integrated PV roofing shingle are also disclosed.

CROSS-REFERENCE TO RELATED APPLICATION

This application relates to and claims the benefit of commonly owned,U.S. Provisional Application Ser. No. 62/964,451, filed on Jan. 22,2020, entitled “INTEGRATED PHOTOVOLTAIC ROOFING SHINGLES, METHODS,SYSTEMS, AND KITS THEREOF,” the contents of which are incorporatedherein by reference in their entirety.

FIELD

The present disclosure relates to integration of photovoltaic (PV)panels into roofing shingles.

BACKGROUND

Traditional rooftop photovoltaic (PV) systems require a large amount ofinstallation labor, as well as specialized tools and methods. Mechanismsto reduce the amount of labor and limit specific requirements forinstalling PV by making the installation more similar to that of arooftop shingle are needed.

SUMMARY

Covered embodiments are defined by the claims, not this summary. Thissummary is a high-level overview of various aspects and introduces someof the concepts that are further described in the Detailed Descriptionsection below. This summary is not intended to identify key or essentialfeatures of the claimed subject matter, nor is it intended to be used inisolation to determine the scope of the claimed subject matter. Thesubject matter should be understood by reference to appropriate portionsof the entire specification, any or all drawings, and each claim.

Some embodiments of the present disclosure relate to an integratedphotovoltaic (PV) roofing shingle comprising: a photovoltaic (PV)module; and a roofing shingle, wherein the roofing shingle is bonded tothe PV module; wherein a bond strength between the roofing shingle andthe PV module is from 5 N/mm to 60 N/mm tested according to ASTM D1876wherein the integrated PV roofing shingle has a mass per unit area of0.5 lb per square foot to 5 lbs per square foot.

In some embodiments, the roofing shingle is bonded to the PV module byat least one adhesive.

In some embodiments, the roofing shingle is a polymer-coated shingle, anasphalt-coated shingle, or a combination thereof.

In some embodiments, the polymer-coated shingle comprises thermoplasticpolyolefin.

In some embodiments, the PV module comprises at least one of: asubstrate, wherein the substrate forms at least a portion of a bottomsurface of the PV module; a superstrate, wherein the superstrate formsat least a portion of a top surface of the PV module; or any combinationthereof.

In some embodiments, the roofing shingle is bonded to at least one of:the substrate, the superstrate, or any combination thereof.

In some embodiments, the top surface of the PV module comprises: a firstportion, wherein the first portion of the top surface of the PV modulecomprises the superstrate; and a second portion, wherein the secondportion of the top surface of the PV module does not comprise thesuperstrate; wherein the roofing shingle is bonded to the second portionof the top surface of the PV module; and wherein the second portion ofthe top surface of the PV module is adjacent to the first portion of thetop surface of the PV module.

In some embodiments, the bottom surface of the PV module does notcomprise a substrate, and wherein the roofing shingle is bonded to thebottom surface.

Some embodiments of the present disclosure relate to a methodcomprising: obtaining a photovoltaic (PV) module and a roofing shingle;bonding the PV module to the roofing shingle, so as to form anintegrated PV roofing shingle having a bond strength, between theroofing shingle and the PV module of from 5 N/mm to 60 N/mm testedaccording to ASTM D1876; and wherein the integrated PV roofing shinglehas a mass per unit area of 0.5 lb per square foot to 5 lbs per squarefoot.

In some embodiments, the bonding step comprises laminating the PV moduleto the roofing shingle.

In some embodiments, the bonding step comprises bonding the PV module tothe roofing shingle with a sufficient amount of bonding material.

Some embodiments of the present disclosure relate to a methodcomprising: obtaining an integrated PV roofing shingle comprising: aphotovoltaic (PV) module; and a roofing shingle, wherein the roofingshingle is bonded to the PV module; wherein a bond strength between theroofing shingle and the PV module is from 5 N/mm to 60 N/mm testedaccording to ASTM D1876; wherein the integrated PV roofing shingle has amass per unit area of 0.5 lb per square foot to 5 lbs per square foot;and affixing the integrated PV roofing shingle to a roof.

In some embodiments, the affixing step comprises affixing the integratedPV roofing shingle to the roof using at least one fastener.

In some embodiments, the at least one fastener is chosen from at leastone nail, at least one screw, at least one staple, or any combinationthereof.

In some embodiments, the integrated PV roofing shingle has 1 fastener to5 fasteners per square foot of the integrated PV roofing shingle afterthe affixing step.

In some embodiments, the fastener is affixed to the roof by driving thefastener through an overlapping area of the integrated PV roofingshingle and into the roof.

Some embodiments of the present disclosure relate to a roofing kitcomprising: a plurality of integrated PV roofing shingles, wherein eachintegrated PV roofing shingle of the plurality of integrated PV roofingshingles comprises: a photovoltaic (PV) module; and a roofing shingle,wherein each roofing shingle of the plurality is bonded to acorresponding PV module; wherein a bond strength between each roofingshingle and each corresponding PV module of the plurality is from 5 N/mmto 60 N/mm tested according to ASTM D1876; wherein each integrated PVroofing shingle of the plurality has a mass per unit area of 0.5 lb persquare foot to 5 lbs per square foot; and wherein each integrated PVroofing shingle of the plurality is configured to be affixed to a roofby at least one fastener.

DRAWINGS

Some embodiments of the disclosure are herein described, by way ofexample only, with reference to the accompanying drawings. With specificreference now to the drawings in detail, it is stressed that theembodiments shown are by way of example and for purposes of illustrativediscussion of embodiments of the disclosure. In this regard, thedescription taken with the drawings makes apparent to those skilled inthe art how embodiments of the disclosure may be practiced.

FIGS. 1-4 are non-limiting embodiments, in cross sectional views, ofexemplary integrated PV roofing shingles according to the presentdisclosure.

FIG. 5 is a top view of an illustrative non-limiting exemplaryembodiment of an integrated PV roofing shingle according to the presentdisclosure.

DETAILED DESCRIPTION

Among those benefits and improvements that have been disclosed, otherobjects and advantages of this disclosure will become apparent from thefollowing description taken in conjunction with the accompanyingfigures. Detailed embodiments of the present disclosure are disclosedherein; however, it is to be understood that the disclosed embodimentsare merely illustrative of the disclosure that may be embodied invarious forms. In addition, each of the examples given regarding thevarious embodiments of the disclosure which are intended to beillustrative, and not restrictive.

Throughout the specification and claims, the following terms take themeanings explicitly associated herein, unless the context clearlydictates otherwise. The phrases “in one embodiment,” “in an embodiment,”and “in some embodiments” as used herein do not necessarily refer to thesame embodiment(s), though it may. Furthermore, the phrases “in anotherembodiment” and “in some other embodiments” as used herein do notnecessarily refer to a different embodiment, although it may. Allembodiments of the disclosure are intended to be combinable withoutdeparting from the scope or spirit of the disclosure.

As used herein, the term “based on” is not exclusive and allows forbeing based on additional factors not described, unless the contextclearly dictates otherwise. In addition, throughout the specification,the meaning of “a,” “an,” and “the” include plural references. Themeaning of “in” includes “in” and “on.”

As used herein, terms such as “comprising” “including,” and “having” donot limit the scope of a specific claim to the materials or stepsrecited by the claim.

As used herein, the term “consisting essentially of” limits the scope ofa specific claim to the specified materials or steps and those that donot materially affect the basic and novel characteristic orcharacteristics of the specific claim.

As used herein, terms such as “consisting of” and “composed of” limitthe scope of a specific claim to the materials and steps recited by theclaim.

All prior patents, publications, and test methods referenced herein areincorporated by reference in their entireties.

As used herein, the term photovoltaic (“PV”) module refers to any devicethat is configured to convert light (e.g., sunlight) into electricpower. A non-limiting example of a PV module is a solar panel.

As used herein, the term “integrated PV roofing shingle” or “integratedphotovoltaic roofing shingle” refers to a roofing shingle that includesa PV module and a roofing shingle, where the PV module and roofingshingle collectively function a single, stand-alone unit. In someembodiments, the “integrated PV roofing shingle” functions as a single,stand-alone unit regardless of whether the “integrated PV roofingshingle” is installed on a roof. While a single integrated PV roofingshingle may function as a stand-alone unit, this does not preclude, forexample, some embodiments where multiple integrated PV roofing shinglesfunction together as a system.

As used herein, the term “bonded” means that two surfaces (e.g., asurface of a PV module and a surface of a roofing shingle) are insufficient contact with each other to provide any bond strength or rangeof bond strengths described herein.

As used herein, the term “superstrate” refers to a layer of a materialdisposed on a top (i.e., sun-facing) portion of a PV module.

As used herein, the term “substrate” refers to a layer of a materialdisposed on a bottom (i.e., ground-facing) portion of a PV module.

In some embodiments, the layer of material of the substrate, thesuperstrate, or any combination thereof comprises an insulating moistureresistant polymer, such as, but not limited to thermoplastic polyolefin(TPO), Ethylene tetrafluoroethylene (ETFE), polyolefin encapsulant(POE), ethylene vinyl acetate encapsulant (EVA), and acrylics. In someembodiments, the layer of material of the substrate, the superstrate, orany combination thereof comprises glass.

As used herein, the term “overlapping area” is defined as themulti-layered section of a shingle where a portion of the headlapsection of the shingle overlaps and contacts a portion of the lowerlayer of the shingle. In embodiments, the overlapping portion of theheadlap section of the shingle is bonded to the corresponding portion ofthe lower layer of the shingle. In embodiments, the overlapping portionof the headlap section of the shingle is bonded to the correspondingportion of the lower layer of the shingle using an adhesive, fastener orcombination thereof. In some embodiments, the overlapping portion of theheadlap section of the shingle is bonded to the corresponding portion ofthe lower layer of the shingle as detailed in U.S. Pat. No. 8,127,514,which is incorporated by reference in its entirety.

Some embodiments of the present disclosure relate to an integrated PVroofing shingle. In some embodiments, the integrated PV roofing shinglecomprises a PV module and a roofing shingle.

In some embodiments, the roofing shingle is bonded to the PV module. Insome embodiments, the roofing shingle is bonded to the PV module bylaminating the PV module to the roofing shingle. In some embodiments,the roofing shingle is bonded to the PV module by at least one bondingmaterial. In some embodiments, the at least one bonding materialcomprises at least one adhesive. In embodiments, the at least oneadhesive includes at least one of: asphaltic adhesives such as rubberpolymer modified asphalt, acrylic adhesives, polyurethane adhesives,silicone adhesives, rubber polymer based adhesives, e.g. SBS, SBR, SEBSand SIS, or any combination thereof.

In some embodiments, a bond strength between the roofing shingle and thePV module is from 5 N/mm to 60 N/mm tested according to ASTM D1876, from10 N/mm to 60 N/mm according to ASTM D1876, from 15 N/mm to 60 N/mmaccording to ASTM D1876, from 20 N/mm to 60 N/mm according to ASTMD1876, from 25 N/mm to 60 N/mm according to ASTM D1876, from 30 N/mm to60 N/mm according to ASTM D1876, from 35 N/mm to 60 N/mm according toASTM D1876, from 40 N/mm to 60 N/mm according to ASTM D1876, from 45N/mm to 60 N/mm according to ASTM D1876, from 50 N/mm to 60 N/mmaccording to ASTM D1876, or from 55 N/mm to 60 N/mm according to ASTMD1876.

In some embodiments, a bond strength between the roofing shingle and thePV module is from 5 N/mm to 55 N/mm tested according to ASTM D1876, from5 N/mm to 50 N/mm according to ASTM D1876, from 5 N/mm to 45 N/mmaccording to ASTM D1876, from 5 N/mm to 40 N/mm according to ASTM D1876,from 5 N/mm to 35 N/mm according to ASTM D1876, from 5 N/mm to 30 N/mmaccording to ASTM D1876, from 5 N/mm to 25 N/mm according to ASTM D1876,from 5 N/mm to 20 N/mm according to ASTM D1876, from 5 N/mm to 15 N/mmaccording to ASTM D1876, or from 5 N/mm to 10 N/mm according to ASTMD1876.

In some embodiments, a bond strength between the roofing shingle and thePV module is from 10 N/mm to 55 N/mm tested according to ASTM D1876,from 15 N/mm to 50 N/mm according to ASTM D1876, from 20 N/mm to 45 N/mmaccording to ASTM D1876, from 25 N/mm to 40 N/mm according to ASTMD1876, or from 30 N/mm to 35 N/mm according to ASTM D1876.

In some embodiments, the roofing shingle is an asphalt-coated shingle, apolymer-coated shingle or any combination/mixture thereof. Non-limitingexamples of the polymer coatings include, thermoplastic polyolefin(TPO), polyvinyl butyral (rPVB), polytransoctenamer rubber (TOR), groundtire rubber (GTR), wood plastic, poly(methyl methacrylate) (PMMA),polyvinyl chloride (PVC), low density polyethylene (LDPE), high densitypolyethylene (HDPE), polypropylene (PP), polyethylene terephthalate(PET). Non-limiting examples of asphalt coatings include oxidizedasphalt coatings and polymer modified asphalt coatings. Non-limitingexamples of polymer modified asphalt coated shingles are described inU.S. Pat. No. 9,493,654, which is incorporated by reference herein inits entirety.

In some embodiments, the integrated PV roofing shingle has a mass perunit area from 0.5 lb per square foot to 5 lbs per square foot, from 0.5lb per square foot to 4.5 lbs per square foot, 0.5 lb per square foot to4 lbs per square foot, from 0.5 lb per square foot to 3.5 lbs per squarefoot, from 0.5 lb per square foot to 3 lbs per square foot, from 0.5 lbper square foot to 2.5 lbs per square foot, from 0.5 lb per square footto 2 lbs per square foot, from 0.5 lb per square foot to 1.5 lbs persquare foot, or from 0.5 lb per square foot to 1 lbs per square foot.

In some embodiments, the integrated PV roofing shingle has a mass perunit area from 1 lb per square foot to 5 lbs per square foot, from 1.5lb per square foot to 5 lbs per square foot, from 2 lb per square footto 5 lbs per square foot, from 2.5 lb per square foot to 5 lbs persquare foot, from 3 lb per square foot to 5 lbs per square foot, from3.5 lb per square foot to 5 lbs per square foot, from 4 lb per squarefoot to 5 lbs per square foot, or from 4.5 lb per square foot to 5 lbsper square foot.

In some embodiments, the integrated PV roofing shingle has a mass perunit area of 1 lbs per square foot to 4.5 lbs per square foot, from 1.5lb per square foot to 4 lbs per square foot, from 2 lb per square footto 3.5 lbs per square foot, or from 2.5 lb per square foot to 3 lbs persquare foot.

In some embodiments, the PV module comprises at least one of: asubstrate, a superstrate, or any combination thereof. In someembodiments, the roofing shingle is bonded to at least one of: thesubstrate, the superstrate, or any combination thereof.

In some embodiments, the substrate forms at least a portion of a bottomsurface of the PV module. In some embodiments, the substrate forms theentire bottom surface of the PV module. In some embodiments, thesuperstrate forms at least a portion of a top surface of the PV module.In some embodiments, the superstrate forms the entire top surface of thePV module.

In some embodiments, the bottom surface of the PV module does notcomprise a substrate. In some embodiments, the roofing shingle is bondedto the bottom surface of the PV module, such that the roofing shinglereplaces the substrate of the PV module. A non-limiting example of anembodiment where a roofing shingle replaces the substrate of a PV moduleis shown in FIG. 3 and described in more detail below.

In some embodiments, the top surface of the PV module does not comprisea substrate. In some embodiments, the roofing shingle is bonded to thetop surface of the PV module, such that the roofing shingle replaces thesuperstrate of the PV module.

In some embodiments, the top surface of the PV module comprises a firstportion and a second portion. In some embodiments, the second portion ofthe top surface of the PV module is adjacent to the first portion of thetop surface. In some embodiments, the first portion of the top surfaceof the PV module comprises the superstrate. In some embodiments, thesecond portion of the top surface of the PV module does not comprise thesuperstrate. In some embodiments, the roofing shingle is bonded to thesecond portion of the top surface of the PV module, such that theroofing shingle replaces the superstrate on the second portion of thetop surface of the PV module. A non-limiting example of an embodimentwhere a roofing shingle replaces the superstrate on the second portionof the top surface of the PV module is shown in FIG. 4 and described inmore detail below.

In some embodiments, the bottom surface of the PV module comprises afirst portion and a second portion. In some embodiments, the secondportion of the bottom surface of the PV module is adjacent to the firstportion of the bottom surface. In some embodiments, the first portion ofthe bottom surface of the PV module comprises the substrate. In someembodiments, the second portion of the bottom surface of the PV moduledoes not comprise the substrate. In some embodiments, the roofingshingle is bonded to the second portion of the bottom surface of the PVmodule, such that the roofing shingle replaces the substrate on thesecond portion of the bottom surface of the PV module.

Some embodiments of the present disclosure relate to a method ofmanufacturing an integrated PV roofing shingle described herein. In someembodiments, the method comprises obtaining a PV module and a roofingshingle. In some embodiments, the method comprises bonding the PV moduleto the roofing shingle, so as to form an integrated PV roofing shinglehaving a bond strength, between the roofing shingle and the PV module,described herein.

In some embodiments, bonding the PV module to the roofing shinglecomprises bonding the PV module to the roofing shingle with a sufficientamount of bonding material, including for example, an adhesive,described herein. In some embodiments, the bonding the PV module to theroofing shingle comprises laminating the PV module to the roofingshingle.

Some embodiments of the present disclosure relate to a method ofinstalling an integrated PV roofing shingle described herein onto a roofIn some embodiments, the method comprises obtaining an integrated PVroofing shingle described herein and affixing the integrated PV roofingshingle to a roof In some embodiments, the integrated PV roofing shingledescribed herein is affixed to a specific portion of a roof. In someembodiments, the specific portion of the roof where the integratingroofing shingle is affixed is a roof deck.

In some embodiments, affixing comprises affixing the integrated PVroofing shingle to the roof using at least one fastener. In someembodiments, the at least one fastener is chosen from at least one nail,at least one screw, at least one staple, or any combination thereof. Insome embodiments, the fastener is affixed to the roof by driving thefastener through an overlapping area (as defined herein) of theintegrated PV roofing shingle and into the roof.

In some embodiments, affixing comprises affixing the integrated PVroofing shingle to the roof using an adhesive. In embodiments, theadhesive may include at least one of: asphaltic adhesives such as rubberpolymer modified asphalt, acrylic adhesives, polyurethane adhesives,silicone adhesives, rubber polymer based adhesives, e.g. SBS, SBR, SEBSand SIS, or any combination thereof.

In some embodiments, the integrated PV roofing shingle has from 1fastener to 5 fasteners per square foot of the integrated PV roofingshingle when the integrated PV roofing shingle is installed on a roof.In some embodiments, the integrated PV roofing shingle has from 2fasteners to 5 fasteners per square foot of the integrated PV roofingshingle when the integrated PV roofing shingle is installed on a roof.In some embodiments, the integrated PV roofing shingle has from 3fasteners to 5 fasteners per square foot of the integrated PV roofingshingle when the integrated PV roofing shingle is installed on a roof.In some embodiments, the integrated PV roofing shingle has from 4fasteners to 5 fasteners per square foot of the integrated PV roofingshingle when the integrated PV roofing shingle is installed on a roof.

In some embodiments, the integrated PV roofing shingle has from 1fastener to 4 fasteners per square foot of the integrated PV roofingshingle when the integrated PV roofing shingle is installed on a roof.In some embodiments, the integrated PV roofing shingle has from 1fastener to 3 fasteners per square foot of the integrated PV roofingshingle when the integrated PV roofing shingle is installed on a roof.In some embodiments, the integrated PV roofing shingle has from 1fastener to 2 fasteners per square foot of the integrated PV roofingshingle when the integrated PV roofing shingle is installed on a roof.

In some embodiments, the integrated PV roofing shingle has from 2fasteners to 3 fasteners per square foot of the integrated PV roofingshingle when the integrated PV roofing shingle is installed on a roof.In some embodiments, the integrated PV roofing shingle has from 2fasteners to 4 fasteners per square foot of the integrated PV roofingshingle when the integrated PV roofing shingle is installed on a roof.In some embodiments, the integrated PV roofing shingle has from 3fasteners to 4 fasteners per square foot of the integrated PV roofingshingle when the integrated PV roofing shingle is installed on a roof.

Some embodiments of the present disclosure relate to a roofing kit. Insome embodiments, the roofing kit comprises a plurality of integrated PVroofing shingles described herein. In some embodiments, the roofing kitcomprises two integrated PV roofing shingles described herein. In someembodiments, the roofing kit comprises three integrated PV roofingshingles described herein. In some embodiments, the roofing kitcomprises four integrated PV roofing shingles described herein. In someembodiments, the roofing kit comprises five integrated PV roofingshingles described herein. In some embodiments, the roofing kitcomprises six integrated PV roofing shingles described herein. In someembodiments, the roofing kit comprises seven integrated PV roofingshingles described herein. In some embodiments, the roofing kitcomprises eight integrated PV roofing shingles described herein. In someembodiments, the roofing kit comprises nine integrated PV roofingshingles described herein. In some embodiments, the roofing kitcomprises ten integrated PV roofing shingles described herein. In someembodiments, the roofing kit comprises twenty integrated PV roofingshingles described herein. In some embodiments, the roofing kitcomprises thirty integrated PV roofing shingles described herein. Insome embodiments, the roofing kit comprises forty integrated PV roofingshingles described herein. In some embodiments, the roofing kitcomprises fifty integrated PV roofing shingles described herein. In someembodiments, the roofing kit comprises one-hundred integrated PV roofingshingles described herein. In some embodiments, the roofing kitcomprises five-hundred integrated PV roofing shingles described herein.

In some embodiments, each integrated PV roofing shingle of the roofingkit is configured to be affixed to a roof by at least one fastenerdescribed herein.

The present disclosure will now be described with reference to severalnon-limiting exemplary embodiments.

FIG. 1 depicts an illustrative non-limiting exemplary embodiment of anintegrated PV roofing shingle according to the present disclosure shownin cross-section. As shown in FIG. 1, an integrated PV roofing shingle100 may comprise a PV module 101 bonded to a roofing shingle 102. Insome embodiments, the integrated PV roofing shingle 100 may comprise abonding material 103 between the roofing shingle 102 and the PV module101. In some embodiments, the PV module 101 of the integrated PV roofingshingle 100 may comprise a superstrate 104 and a substrate 105.

FIG. 2 depicts an illustrative non-limiting exemplary embodiment of anintegrated PV roofing shingle according to the present disclosure, alsoshown in cross-section. As shown in FIG. 2, integrated PV roofingshingle 200 may comprise a PV module 201 bonded to a roofing shingle202. Roofing shingle 202 may, in some embodiments, comprise twoportions—first portion 202 a and second portion 202 b. In someembodiments, first portion 202 a is a top portion as shown. In someembodiments, second portion 202 b is a bottom portion as shown. However,this configuration is not limiting. The first portion 202 a and secondportion 202 b of the roofing shingle 202 may, in some embodiments, be incontact at overlapping area 202 c. In some embodiments, at least onefastener (not shown) may be driven into overlapping area 202 c, so as toaffix integrated PV roofing shingle 200 to a roof (not shown). In someembodiments, the integrated PV roofing shingle 200 may comprise a firstbonding material 203 a and a second bonding material 203 b. In someembodiments, first bonding material 203 a and second bonding material203 b are the same. In some embodiments, first bonding material 203 aand second bonding material 203 b are different. In some embodiments,the PV module 201 of the integrated PV roofing shingle 200 may comprisea superstrate 204 and a substrate 205. In some embodiments, firstbonding material 203 a is disposed between the superstrate 204 and thefirst portion 202 a of the roofing shingle 202. In some embodiments,second bonding material 203 b is disposed between the substrate 205 andthe first portion 202 b of the roofing shingle 202.

FIG. 3 depicts an illustrative non-limiting exemplary embodiment of anintegrated PV roofing shingle according to the present disclosure, alsoin cross-section. As shown in FIG. 3, integrated PV roofing shingle 300may comprise a PV module 301 bonded to a roofing shingle 302. In someembodiments, the PV module 301 of the integrated PV roofing shingle 300may comprise a superstrate 304. In some embodiments, the PV module 301of the integrated PV roofing shingle 300 may not include a substrate,such that the roofing shingle 302 replaces the substrate, as shown.

FIG. 4 depicts an illustrative non-limiting exemplary embodiment of anintegrated PV roofing shingle according to the present disclosure incross-section. Roofing shingle 402 may, in some embodiments, comprisetwo portions—first portion 402 a and second portion 402 b. The firstportion 402 a and second portion 402 b of the roofing shingle 402 may,in some embodiments, be in contact at overlapping area 402 c. In someembodiments, a fastener (not shown) may be driven into overlapping area402 c, so as to affix integrated PV roofing shingle 400 to a roof (notshown). In some embodiments, the PV module 401 of the integrated PVroofing shingle 400 may comprise a superstrate 404. In some embodiments,a top portion 401 a of the PV module 401 does not comprise thesuperstrate 404. In some such embodiments, a portion of the superstrate404 is replaced with portion 402 d of the roofing shingle 402 on topportion 401 a of the PV module as shown. In some embodiments, theportion 402 d of the roofing shingle 402 that is disposed on top portion401 a of the PV module 401 is adjacent to the superstrate 404 as shown.

FIG. 5 depicts a top view of an illustrative non-limiting exemplaryembodiment of an integrated PV roofing shingle according to the presentdisclosure. As shown in FIG. 5, integrated PV roofing shingle 500 maycomprise a PV module 501 bonded to a roofing shingle 502. In someembodiments, integrated PV roofing shingle 500 may comprise a fastenerapplication area 507.

Variations, modifications and alterations to embodiments of the presentdisclosure described above will make themselves apparent to thoseskilled in the art. All such variations, modifications, alterations andthe like are intended to fall within the spirit and scope of the presentdisclosure, limited solely by the appended claims.

While several embodiments of the present disclosure have been described,it is understood that these embodiments are illustrative only, and notrestrictive, and that many modifications may become apparent to those ofordinary skill in the art. For example, all dimensions discussed hereinare provided as examples only, and are intended to be illustrative andnot restrictive.

Any feature or element that is positively identified in this descriptionmay also be specifically excluded as a feature or element of anembodiment of the present as defined in the claims.

The disclosure described herein may be practiced in the absence of anyelement or elements, limitation or limitations, which is notspecifically disclosed herein. Thus, for example, in each instanceherein, any of the terms “comprising,” “consisting essentially of and“consisting of” may be replaced with either of the other two terms,without altering their respective meanings as defined herein. The termsand expressions which have been employed are used as terms ofdescription and not of limitation, and there is no intention in the useof such terms and expressions of excluding any equivalents of thefeatures shown and described or portions thereof, but it is recognizedthat various modifications are possible within the scope of thedisclosure.

The invention claimed is:
 1. An integrated photovoltaic (PV) roofingshingle comprising: a photovoltaic (PV) module; wherein the PV modulecomprises: i) a polyolefin (POE) layer having a bottom surface and a topsurface opposite the bottom surface, and ii) a substrate having a topsurface and a bottom surface, the top surface of the substrate on thebottom surface of the POE layer, the substrate comprising at least onematerial from the group consisting of a thermoplastic polyolefin,ethylene tetrafluoroethylene, polyolefin encapsulant, ethylene vinylacetate encapsulant, and acrylics; and a roofing shingle comprising atop surface and a bottom surface, wherein the roofing shingle comprisesa thermoplastic polyolefin (TPO) layer, wherein the top surface is acontinuous flat surface, wherein the continuous flat surface of theroofing shingle is bonded to the bottom surface of the substrate of thePV module by a bonding material; wherein a bond strength between theroofing shingle and the substrate of the PV module is from 10 N/mm to 60N/mm tested according to ASTM D1876; and wherein the integrated PVroofing shingle has a mass per unit area of 0.5 lb per square foot to 5lbs per square foot.
 2. The shingle of claim 1, wherein the bondingmaterial comprises an adhesive.
 3. The shingle of claim 2, wherein theadhesive comprises at least one of: an asphaltic adhesive, an acrylicadhesive, a polyurethane adhesive, a silicone adhesive, and a rubberpolymer based adhesives.
 4. A method comprising: obtaining an integratedPV roofing shingle comprising: a photovoltaic (PV) module; wherein thePV module comprises i) a polyolefin (POE) layer having a bottom surfaceand a top surface opposite the bottom surface, and ii) a substratehaving a top surface and a bottom surface, the top surface of thesubstrate disposed on the bottom surface of the POE layer, the substratecomprising at least one material from the group consisting of athermoplastic polyolefin, ethylene tetrafluoroethylene, polyolefinencapsulant, ethylene vinyl acetate encapsulant, and acrylics; and aroofing shingle comprising a top surface and a bottom surface oppositethe top surface, wherein the roofing shingle comprises a thermoplasticpolyolefin (TPO) layer, wherein the top surface is a continuous flatsurface, wherein the continuous flat surface of the roofing shingle isbonded to the bottoms surface of the substrate of the PV module by abonding material; wherein a bond strength between the roofing shingleand the substrate of the PV module is from 10 N/mm to 60 N/mm testedaccording to ASTM D1876; and wherein the integrated PV roofing shinglehas a mass per unit area of 0.5 lb per square foot to 5 lbs per squarefoot; and affixing the integrated PV roofing shingle to a roof using atleast one fastener, wherein the fastener comprises at least one nail. 5.The method of claim 4, wherein the integrated PV roofing shingle has 1fastener to 5 fasteners per square foot of the integrated PV roofingshingle after the affixing step.
 6. The method of claim 4, wherein thefastener is affixed to the roof by driving the fastener through anoverlapping area of the integrated PV roofing shingle and into the roof.7. The method claim 4, wherein the bonding material comprises anadhesive.
 8. The method of claim 7, wherein the adhesive comprises atleast one of: an asphaltic adhesive, an acrylic adhesive, a polyurethaneadhesive, a silicone adhesive, and a rubber polymer based adhesives.